Conductor



June 23, 1936. E, M, DEEMS 2,045,126

CONDUCTOR Filed May 23:, 1 931 Patented June 23, 1936 UNirED STATES.PATENT OFFICE- CONDUCTOR Edward M. Deems, Forest Hills, N. Y., assignorto Railroad Accessories Corporation, New York, N. Y., a corporation ofNew AYork Application May 21, 1931, serial No. 538,943 12 claims. `(c1.17a- 280) This invention relates toconductors, more especially toconductors for connecting the adja-y cent ends of railway rails,particularly those for use in connection with railway track circuits.

It is well understood by those skilled in the railway signalling art,that ay track circuit includes an insulated section of the trackwayformed by placing insulating joints in each of the lines of rails, andby connecting a battery across the rails at ne end,and a relay acrossthe rails at the other end.

It is also well understood that the ordinary rail connecting or fishplates connecting the adjacent ends of the ordinary thirty-six footsections are not to be relied upon to furnish suihcient conductivity forthe electrical energywhich ows in the rails from the battery at one endof the section to the relay at the other end thereof. This fact hasnecessitated a special bonding of each of the adjacent abutting railends within the section. y

Great difllculties have been encountered in successfully bonding theadjacent abutting rail ends in track circuit sections because provisionhas to be made for many adverse conditions. A common method is to bond,from one rail web to the adjacent rail web, by means of one or aplurality N of conductors of a length somewhat greater than the lengthof the ish plates.` 'I'his method of bonding exposes the bonding wiresto mechanical injury, in that they may become entangled with draggingparts from the rolling stock, or may actually get onto the top of, therail, and so be severed by the passage thereover of the `wheels ofrolling stock. In addition. they are very likely to be damaged bytrackmen when working along the track, particularly vwhen working in andabout the rail joint, and more especially when tightening the boltsthereof, or replacing the sh plates with new plates. J, A verypronounced dilculty with the old type of bond is, that du to its lengthand in spite of its size as it may' e commercialy used, it does notoffer a conductivity as great as is desired. The desired conductivitycannot `be attained without enlarging the bond `to a prohibitive extent.

n Attempts have been made to increase the conductivity and decrease themechanical disadvantages of bonds by applying a bond directli,7 to therail heads. Such'a bond can be very short, as compared with thepreviously described bond, therefore, Afor a given diameter has anincreased conductivity inthat it has less resistance. Such bonds have,in general, been applied to the head 55 of the rail by electrical or amewelding. Many competent engineers are adverse to applying anyconsiderable degree of heat to the side of the ball of a rail,especially adjacent the end thereof, and this reluctance, considered bymany to' be well founded, has militated against the use of such 5 bonds.

A further diiiiculty which has been met with in the type of bond applieddirectly to the 'rail heads is that it is particularly exposed to injuryby snow ploughs and ballast spreadel's. Both of l0 these devices,and-especially the ballast spreader, have parts which extend below thetop surface of the head of the rail on the outside thereof. These parts,due to the swaying of the vehiclecome in contact with the head of railbonds and destroy l5 them.

Attempts:` have been made to attach bonds to rail heads. by drilling acavity in-the rail head and attaching the bond to a plug driven into thecavity. A difliculty with this type of ,bond arises 20 from the factthat it is necessary to drill a relatively deep hole in the head of therail. This hole penetrates what might be called the activecross-sectional area. of the head and to that extent weakens the railhead.

A principal object of the present invention'is the production of a bondwhich will obviate mt of the defects of the type of bonds' hereinbefore'described which are connected from rail web to rail web. and which onthe other hand will have 30 the desirable virtues of a rail bondconnected from rail head to rail head, and will be free from most of theundesirable characteristics of the emanen or name welded bonds, and'will also be free fromthe important'undesirable character- 85 istics ofthe mechanically attached rail head bond.

A further object of the invention is the production of a bond of therail head connected type which has the advantages speciiled, and whichwill further be of such a construction that it 40 may be applied torails without the, necessity for the cumbersome, expensive, and unusualappa# ratus, and tools commonly required for the aflixing of anelectrical `or flame welded bond.

` A further object of the invention is' the pro- 45 duction of a bond ofthe type described, which will be of a construction such that it will beo'f high conductivity, mechanically strong, and of small compass.

A further object of the invention is the' produc- 50 tion of a bond ofthe type described which will beofsuch construction that the likelihoodof being caught and damaged by dragging parts of rolling stock will begrcately A further object ofthe invention is the pro- |55 duction of abond of the type described which will be of such construction that itwill be substan- 'tially immune from injury by snow ploughs andespecially ballast spreaders.

A further object of the invention is the production of a bond of thetype described which ywill be of such construction that it will not benecessary to drill a hole in the rail head to a depth which willpenetrate what might be called the active cross-section thereof.

Other objects and advantages will appear as.

vjacent rail ends with the improved bond of thel invention in placethereon; Fig. 2 is a topplan View of the arrangement as shown in Fig. 1,with A some parts broken away and others in cross-section in order tomore clearly show the construction; Fig. 3 is a fragmentary enlargedview showing the initial positioning of parts of the improved bond; Fig.4 is a perspective view of oneA of the parts of my improved bond whichis designated by me as a plug; Fig. 5 is a perspective view of one ofthe parts of my improved bond which has been designated by me as aterminal; Fig. 6 is a fragmentary enlargedview similar to Fig. 3illustrating a modified form of terminal and plug; Fig. 1 is afragmentary enlarged view similar to Fig. 3 showing another modified'form of plug; Fig. 8 is a fragmentary enlarged view similar to Fig. 3but showing the plug of Fig. I in its nal condition; Fig. 9 is afragmentary enlarged view similar to Fig. 3 but showing a modified formof plug; Fig. 10 is a fragmentary enlarged view similar to Fig. 3showing a further modified form of plug; Fig. l1 is a diagrammatic viewillustrating the active load bearing cross-section of a rail.

Two adjacent rails I and 2 are shown in Fig. l. These rails are shown inelevation. The webs are 3 and 4, and the heads extend between the lines5 and 6. As shown in Fig. 2, the flange side of the rail is `I and theoutside face is 8.

In order to electrically bond the rail I to the rail 2, using as short aconductor as possible, a

cavity' 9 is formed in each rail head. This cavity is formed anappropriate distance back from the end of the rail so that the conductoras III will notv be too long. 'I'he cavity is alsoformed low down on thehead of the rail, as most 1clearly shown .in Fig. 1, and is extremelyshallow. In practice, the cavity'would be about three-eighths of an inchin diameter and the cylindrical portion about one-eighth o'f an inch indepth. Such a cavity could be formed in what is virtually inactivematerial of the rail, that is, the cavity would not be of such depth asto penetrate, what might be called, the active cross-section oi the railhead, or'the portion ofthe rail head which acts to sustain the load. Acavity so formed would have no effect in decreasing the strength of therail and consequently would be entirely unobjectionable.- Such a cavitydiffers from those previously formed in similar situations because theprevious cavities have been of a very considerable depth, penetratingthe active load bearing cross-section of the rail and suitable forreceiving the ordinary and well known tapered bond plug.

The relation of the cavity to the other portion of the rail head is mostclearly shown in Fig.

ll, in which 9 is the cavity, and the active load 5 bearingcross-section of the rail is the area between the dotted lines 20 and 2I. In order to conductively connect the conductor as I0 at each end inthe cavities in the rail heads, applicant makes use of a plug. This plugis not 10 of the ordinary and usual form, that is, it does notcorrespond to the ordinary tapered plug used in rail head bonding and inrail web bonding because applicants plug is not secured or fixed inposition in the cavity by the binding action or 15 friction between twosurfaces one of which is not exactly parallel to the other, that is, oneof which is tapered very slightly. Applicants method of afxing a 4plugin a cavity is by expanding the plug, in the cavity, against the wallwhich-is at right angles to the outside face of the rail. In none of theexamples illustrated in the drawing is the plug held in the cavity byfriction between two surfaces one of which is slightly tapered,but inall cases the plug is held in the cavity merely 25 by reason of thedegree of pressure by which it is pressed toward the surface of thecavity.

Applicants plug, or disc, may be made in various forms and the meanscooperating between the plug and the conductor at I0 may take variousforms, in fact, applicant does not intend to exclude, by his particularshowing, a construction in which the plug and the conductor I0 areintegral, but in the preferred form as shown in the drawing theconductor is associated in all cases with what is known as a terminalwhich in turn cooperates with a plug.

In the particular preferred form of conductor terminal designated, as awhole, by T, and shown in Fig. 5, there is included substantially anannulus II. This annulus Il is of such an outside diameter that itsubstantially fits or contacts the cylindrical wall portion of cavity 9.It is preferred to form an end wall I2 on the annulus I I, and to havethis end wall formed so as to substan- 4" tially t the end wall I3 of acavity 9. It is further preferred to extend the annulus II -such adistance that sulllcient material will be provided by which a skirt I4may be formed which r may be curved tightly about the conductor I0 so asto make intimate, mechanical, and electrical contact therewith. Thiscontact may be materially enhanced by electrically welding or solderingthe 'conductor I0 to the skirt II4 as at I5.

In practice applicant prefers to associate the conductor I0 with theterminals T, one at each end of the conductor, at the factory.

Placing applicants bond on rails consists in forming cavities as 9 ineach of the adjacent rail heads, and, by cavity, applicant means a spacehaving at least one end'wall, as distinguished from a'through hole. Thiswould be done by drilling as is customary, with the ordinary twistdrill, ofusual commotion. Such drilling would form a cavity 9 having acylindrical portion and an end wall portion of conical form. Theconductor III, having a. terminal T at each end thereof, would bepositioned against the rails and a terminal placed in each of thecavities. It would then be necessary to place a plug within each of theannuli and properly expand it.

Various forms of plugs may be used by applif cant but the preferred formis that shown in Figs.

with one base formed substantially hemispherical and the other conical.The diameter of the cylindrical portion is preferably greater than thetotal length of the plug. In practice, the length of the cylindricalportion would be about one-eighth of an inch, for a plug three-eights ofan incnin diameter. The length of the conical portion would correspondto that necessary to substantially t the end wall, andthe length ofthehemispherical portion could be adjusted so that i after the plug isin position and driven home it will not extend substantially beyond theedge of thecavity.

Using a plug such as I6 it would be first placed in the annulus asshownv in Fig. 3, and then a punch such as Il forced against the plug I6in any suitable manner, as by' striking or screw pressure or leverage,sufficiently to force the plug into a condition substantially as shownby Fig. 2, that is, to exert a very considerable force against theoutside end face of the plug so that while the plug is supported by theend wall of the cavity it is squeezed and expanded laterally so as topress rmly and xedly against the inside wall of the annulus thus actingto force the outside Wall of the annulus into close mechanical andelectrical contact with the inside surface of the' wall of the cavity 9.

Bonds constructed, arranged and anxed as hereinbefore described providea suitable conductivity, are out of the way of dragging, rolling stock,flanges and. snow ploughs, may be anxed without the use of large andcumbersome tools, unsuitable for handling by one man, and when amxed arepermanent, 'and so closely connected mechanically with the insidesurface of the cavity 9 that the bond must be practically destroyed inorder to Wrench it from its position.

In practice applicant prefers to make the conductor I0, the terminal T,and the plug I6 all of copper, but applicant does not intend to eX-cludeby such Aspecification the use of other and suitable material such,for instance, as mild steel for the plug, or brass or mild steel for theterminal T, or copper clad steel for the conductor I0.

A most distinctive characteristic of applicants invention is the plug |6and the method of alxing in position. No reliance for the maintenance ofthis plug in its fixed position is placed on contacts between taperedsurfaces, but reliance is placed upon such a contact pressure betweenthe outside surface of the plug and the inside surface of the annulus'orthe cavity as will be suincient to properly retain the plug in place. Itis to be further observed, that when the bond is placed in position withthe terminal T in the cavity and the plug I6 within the terminal, thatthen no matter how much pressure is applied to the plug I6, there issubstantially no relative movement between the body and the plug I6 andthe annulus II so that there is no tendency to tear the annulus II. 'Iheplug while being expanded laterally is supported by` the end wall of thecavity and pressed upon by the end surface .of the member I1.

Various 'other forms of terminals and plugs may be used in carrying outapplicants invention. In Fig. 6 a plug I6 is shown which correspondswith plug I6 except that one base instead of being conical issubstantially flat. With this form of plug a terminal T is used whichhas an end wall` I2 which is at and square across. With this form ofplug and terminal, the vfirst eifect of the pressure from the punch I1is to force the `central portion of the plug I6' to the end wall of thecavity 9 together with the end wall I2'. When these portions have becomeseated, further pressure merely results in lateral expansion of the plugI6'.

In Fig. 7 a plug I62 is shown. 'Ihis plug is concavo-convex in form.Pressure on the punch I1 straightens out the plug |62 into the form asshown byFig. 8. 'Ihis straightening out causes a very decided lateralexpansion. In this form 'of plug the thrust of the punch I 'I isresisted by the end wall I3 of the cavity 9, because the plug |63 alongits insideedge bears against the terminal T which in turn is supportedby the end wall.

In Fig. 9 a plug |63 is shown. 'I'his plug has a central cavity I8formed therein. Plug |63 is laterally expanded by using a tapered plugI9. This tapered plug I9 is driven into the cavity |8. 'I'he plug |63 isprevented from moving endwise by reason ofits support by the end Wall I3of the cavity-"9 so that the Whole eiect of driving the tapered plug I9into the cavity I8 is to laterally expand the plug |63.

A piug |63 as shown in Fig. 1o may also be expanded by a punch l,I'Iwhich is withdrawn after the plug |63 has been suitably expanded.

This punch |'I' bears a reduced portion I9' which serves just as thetapered plug I8 does to enter the cavity I8 of the plug ||3 and expandthe same, but after the expansion has been accomplished the punch vI1'with the reduced member I9 thereon is withdrawn.

Although I .have particularly described the principle, construction andmode of operation of particular physical embodiments of my invention,

nevertheless, I desire to have it understood that the forms selected aremerely illustrative but do not ,exhaust the possible physicalembodiments of the idea of means underlying my invention.

What II claim as new and desire to secure by Letters Patent of theUnited States, is:

1. The method of xing a body having a sub- -stantially axial recess in arail cavity of uniform4 bore which consists in supporting said body byan end Wall of said cavity while forcing into the recess of said body anexpander body of owable metal, spreading the expander body laterally andshortening it longitudinally and thereby spreading the Walls of saidfirst-named body, and holding it under compression against thecircumjacent walls of said cavity.

2. In a rail bond, in combinationz` a conductor having a terminal formedf with a recess and means for conductively attaching the conductor to arail head having a cavity of uniform bore formed with an end wall, saidmeans including a. body adapted to be expanded in saidrecess andvthereby to expand said terminal in said cavity while supported by anend wall of the cavi against substantial displacement bodily.

3. In a railway bond, in combination: a conductor; terminals, one oneach end of the conductor, each of said terminals including an annularportion adapted to t into-a cavity in a rail and lie against acylindrical wall thereof; deformable plugs, one fitting within eachannulus. and adapted to be supported by the end Wall of the cavity inthe rail whereby pressure Vexerted against the plug expands the pluglaterally, binding the annulus mechanically and electrically to therail.

4. In a rail bond, in combination: ,a conductor; annuli, one at, eachend of the conductor, adapted to be positioned in a cavity in a railhead.- said annuli having one edge rolled over, substantially rail whichconsists in rst forming a cavity in the rail, then placing therein anannulus with its outer surface in contact with an inner surface of thecavity and having a conductor connected thereto, then inserting withinthe annulus a disc, and then spreading the disc so as to force the disctightly against the inner surface of the annulus and the outer surfaceof the annulus against the inner surface of the cavity.

6. The method of attaching a conductor to a rail which consists inattaching a conductor conductively to a conducting member bearingagainst the inside surfaces of a rail cavity and then expanding a bodyof resistantly yielding owable material against the said member so as tohold the member tightly in contact with the said surface while themember is supported by the end wall vof the cavity. y

'1. In a rail bond, in combination: a conductor;

Ahollow terminals, one at each end of the conductor; discs, one for eachterminal, each disc being of a diameter allowing the disc to readilyenter its respective hollow terminal and each of said discs beingreadily flattened and thereby increased in diameter so as to be therebyretained in a cavity in a rail while being supported by the end wall ofthe cavity.

8. The methodof electrically bonding to a rail which comprises formingai cavity in the side of a rail head so far down thereon and of suchshallowness as to be substantially without the active load bearingcross-section of the rail and 0 amxing therein an electrical conductor.

9. The method of electrically bonding to a rail which comprises forminga cavity in the side of a'raiiv head so far down thereon and of suchshallowness as to obviate substantial encroachment upon the active loadbearing cross-section of the rail and ailixing therein an electricalcon` 5 ductor.

10. In combination with a rail having a head and a supporting web. saidhead having in a lateral face at a region remote from the upper surfaceof the head a cavity extending to a depth lo at which it is free fromsubstantial encroachment upon the active load bearing cross-section ofthe head, an electrical connector having a hollow terminal extendingwithinsaid cavity, and a separately formed metal plug within said hollowterminal and expanded to hold the walls of said terminalunder'compression against the inner walls of said cavity.

l1. In combination with a'rail having a head and a supporting web, saidhead having in a lateral face at a region remote from the upper surfaceof the head a cavity extending to a depth at which it is free fromsubstantial encroachment upon the active load bearing cross-section ofthe head. an electrical connector having a hollow terminal extendingwithin said cavity, and

a separatelyformed metal plug within said hollow terminal and expandedlaterally to a dimension in excess of its axial extent, whereby it holdsthe walls of said terminal under compression against the inner walls ofsaid cavity.

12. The combination with a rail bond provided with a terminal of mildsteel having an annular part adapted to enter a bonding cavity in arail, of an expansible plug of copper positioned axially of said annulusand expandible laterally to bind said terminal to the inner walls ofsaid cavity, said plug being restrained from bodily longitudinalmovement by the end wall of said cavity.

EDWARD M. DEEMs.

